Small Parts Storage Container

The present disclosure claims priority to United States Provisional Patent Disclosure Ser. No. 63/774,027 filed Mar. 18, 2025.

The present disclosure relates to containers, and more specifically to a tray with multiple compartments, each with a removable cover.

There are many storing and organizing systems for storage of electronic devices such as resisters for use in manual repair, rework, and building of circuit boards.

Surface mount resistors are typically provided in reels of tape that typically hold several thousand resistors. The reels of tape are designed for use with automated pick and place equipment for manufacturing circuit boards. The tape has individual compartments for each resistor and a plastic film over the tops of the compartments to prevent the resistors from falling out. This film needs to be peeled back from the compartments in order to access the resistors. But reels of tape are not convenient for storing small quantities and a large assortment of values such as is needed in repair work or hand building of a circuit board.

Existing storage systems such as trays with hinged lids on each compartment, individual containers with removable covers, and 3-ring binders having pages with pockets to hold strips of tape all are workable solutions but have drawbacks that may make them inconvenient. 3-ring binders are bulky and typically hold strips of the tape that contain the components as it comes from a reel of parts. Accessing a component involves first finding the page in the binder that has the part and then removing the strip of tape from a pocket in the binder and finally removing the part from the tape. And then the tape has to be put back into the binder.

Trays with hinged lids are bulky and have the added complexity of the hinge mechanism. Individual containers with removable covers need an additional organizer to store the individual containers.

This background section is intended to introduce the reader to various aspects of art that may be related to various aspects of the present disclosure, which are described and/or claimed below. This discussion is believed to assist the reader with background information to facilitate a better understanding of the various aspects of the present disclosure. Accordingly, it should be understood that these statements are to be read in this light, and not as admissions of prior art.

A cover for a container assembly according to one disclosed non-limiting embodiment of the present disclosure includes a top section; a bottom section; a first and second longitudinal side between the top section and the bottom section; and; a first and second lateral side between the top section and the bottom section.

A further embodiment of any of the foregoing embodiments of the present disclosure includes, wherein a recess in the top, the recess comprises a lip and an undercut, the undercut forms an acute angle with the surface of the top section, wherein the recess is fingernail shaped.

A further embodiment of any of the foregoing embodiments of the present disclosure includes, wherein a flanged upper section about the top section, the flanged upper section defines a periphery larger than a periphery defined by the sides.

A further embodiment of any of the foregoing embodiments of the present disclosure includes, wherein a chamfered bottom section about the bottom section, the chamfered bottom section defines a periphery smaller than a periphery defined by the sides.

A further embodiment of any of the foregoing embodiments of the present disclosure includes, wherein the first and second longitudinal side define an interference fit within a compartment in a tray within which the cover is installed.

A further embodiment of any of the foregoing embodiments of the present disclosure includes, wherein the interference fit is between 101-105% the length of the longitudinal length of the compartment.

A further embodiment of any of the foregoing embodiments of the present disclosure includes, wherein the first and second lateral side define a clearance fit within a compartment in a tray within which the cover is installed.

A further embodiment of any of the foregoing embodiments of the present disclosure includes, wherein the first and second longitudinal side define an interference fit within a compartment in a tray within which the cover is installed and the first and second lateral side define a clearance fit within a compartment in a tray within which the cover is installed.

A further embodiment of any of the foregoing embodiments of the present disclosure includes, wherein the interference fit is between 101-105% the length of the longitudinal length of the compartment.

A further embodiment of any of the foregoing embodiments of the present disclosure includes, wherein the cover and the tray are additively manufactured.

A further embodiment of any of the foregoing embodiments of the present disclosure includes, wherein the cover and the tray are additively manufactured of different materials.

A further embodiment of any of the foregoing embodiments of the present disclosure includes, wherein the cover and the tray are injection molded.

A further embodiment of any of the foregoing embodiments of the present disclosure includes, wherein the cover and the tray are injection molded of different materials.

A further embodiment of any of the foregoing embodiments of the present disclosure includes, wherein a recess in the bottom section.

A container assembly according to one disclosed non-limiting embodiment of the present disclosure includes a tray with a multiple of compartments; a cover that fits at least partially within at least one of the multiple of compartments, the cover comprises: a top section; a first and second longitudinal side between the top section and a bottom section; and a first and second lateral side between the top section and the bottom section, wherein the first and second longitudinal side define an interference fit within a compartment in a tray within which the cover is installed and the first and second lateral side define a clearance fit within the compartment in the tray within which the cover is installed.

A further embodiment of any of the foregoing embodiments of the present disclosure includes a recess in the top section, the recess comprises a lip and an undercut that forms an acute angle with the surface of the top section.

A further embodiment of any of the foregoing embodiments of the present disclosure includes an interference fit that is between 101-105% the length of the longitudinal length of the compartment.

The foregoing features and elements may be combined in various combinations without exclusivity, unless expressly indicated otherwise. These features and elements as well as the operation thereof will become more apparent in light of the following description and the accompanying drawings. However, it should be appreciated that the following description and drawings are intended to be exemplary in nature and non-limiting.

1 FIG. 20 30 40 50 20 schematically illustrates a container assemblythat generally includes a traywith a multiple of compartments, each of which has a cover. The container assemblymay be used for storing and organizing small electronic components such as resistors and capacitors, small fasteners, craft items, and many other small items.

40 40 50 50 In embodiments, the compartmentsmay be rectangular in shape. Rectangular compartmentshave rectangular covers and rectangular covershave the advantage of being able to be put in place backwards. A coverput in place backwards can be used as an indicator that the compartment is empty or low on parts. Other shapes can also be put on in more than one orientation, for example equilateral triangles and regular hexagons.

The size and number of compartments in a tray depends on what items may be stored therein. The shape would typically be rectangular, with the length, width, and depth again being dependent on the items being stored. The number of compartments in a tray will depend on the application. For example, one hundred (100) or more compartments in a tray provides easy access to a large assortment of parts. In other cases, it might be useful to have a tray with a much smaller number of compartments. For example, if there is a repair job that gets done frequently and only 15 different parts are ever needed for the repair, a tray with 15 compartments might be convenient.

For many applications, all compartments will be the same size, but that is not required. A tray could have several different sized compartments, although each may typically have the same depth.

2 2 FIGS.A,B 3 3 FIGS.A,B 50 52 54 56 56 50 58 52 60 56 56 50 40 With reference to, and, in the embodiment in which the stored items may be resistors, the covermay generally include a top section, a bottom section, and sidesA-D. The covermay further include a flanged upper sectionin which the top sectionis larger than a peripherydefined by the sidesA-D of the coveras well as the periphery of the compartment.

50 62 60 50 40 62 58 40 40 50 50 40 50 40 58 40 3 3 FIGS.A,B The covermay further include a chamfered bottom sectionthat is smaller than the peripheryof the coveras well as the periphery of the compartment. The chamfered bottom sectionand the flanged upper sectionfacilitates installation and removal of the cover from each individual compartment. The compartmentis sized to provide an interference fit with the cover, that is, the coveroperates to plug into an associated compartmentand remains therein via friction. In this embodiment, the compartment may be about 13 mm long, and the coverextends into the compartmentfor a depth of about 2.98 mm into a 10.5 mm deep compartment () with the flanged upper sectionresting above the lip of the compartment.

50 30 50 30 50 In embodiments, the covermay be manufactured of a pliable material such as a thermoplastic elastomer, rubber, silicone, flexible 3D filament, etc. The trayand the coversmay be manufactured using injection molding or using fused filament fabrication, commonly called 3D printing or additive manufacturing. Alternatively, or in addition, the trayand the coversmay be manufactured of an at least partially translucent material to visually identify the items.

2 3 FIGS.A andA 2 3 FIGS.B andB 2 3 FIGS.A andA 2 3 FIGS.A andA 40 50 40 40 In embodiments, the interference fit need not be equivalent along both axes and may, in embodiments, be greater along the longitudinal axis (). That is, the dimension along the lateral axis () may provide a clearance fit while the longitudinal axis () provides the interference fit. In one embodiment in which the compartmentis 13 mm, the longitudinal axis () of the coveris between 101-105% the length of the longitudinal length of the compartment, and in one embodiment is about 103.4% the length of the longitudinal length of the compartment.

50 40 50 2 3 FIGS.B andB The process of removing the coverfrom the cavityinvolves applying a force parallel to the top surface of the cover and also a force perpendicular to that surface to lift it away from the compartment. The force parallel to the surface has the effect of compressing the springiness of the cover. But compressing the coverin one axis causes it to expand slightly in the horizontal axis perpendicular to the force. For that reason, the cover may be fabricated slightly narrower in the lateral axis () where the expansion occurs to minimize or eliminate binding.

40 50 50 In embodiments, one or more walls of the compartmentand/or the covermay include a textured section to increase the friction to retain the covers.

54 50 70 40 50 70 40 3 3 FIGS.A andB In embodiments, the bottom sectionof the covermay include a bottom recess() to further increase storage space in the compartment, reduce cost, and/or reduce the stiffness of the cover. The recessmay alternatively or additionally be shaped to at least partially conform to an item within the compartment.

4 4 FIG.A-C 3 FIG.A 52 50 80 50 80 82 84 84 52 80 90 50 With reference to, in embodiments, the top sectionof the covermay include a recessto facilitate the removal of the cover. The top recessmay be essentially fingernail shaped with a lipand an undercutto facilitate grip by a fingernail, or tool. That is, the undercutforms an acute angle with the surface of the top section(best seen in). The top recessmaintains a planar top surface to facilitate stacking of the trays as well as a marking section areaon each cover. In embodiments, the markings can be adhesive labels, printed, molded when fabricated, achieved with a laser, etc. The laser may alter or remove pigment in the cover, rather than etching into the cover or burning it to change its color. The end result is a marking of a lighter color than the surrounding material of the cover. An ultraviolet laser works well to remove or change the color of pigments in plastics.

Each cover may be marked after it is in place based on its location. That means that there is one generic cover that gets used on all similar compartments rather than having to stock a separate cover for each compartment. In the example of 1% tolerance resistors, there are 673 standard values covering the range from 1 Ω to 10 MegΩ. If the covers are marked after they are placed on the trays, only one generic unmarked cover needs to be stocked rather than the 673 needed if they are marked before being placed.

30 50 gold 1.00 Ω-9.76 Ω black 10.0 Ω-97.6 Ω brown 100 Ω-976 Ω red1.00 kΩ-9.76 kΩ orange 10.0 kΩ-97.6 kΩ yellow 100 kΩ-976 kΩ green 1.00 MΩ-9.76 MΩ In embodiments, the trayand/or the covermay alternatively or additionally be color coded. In the case of an assortment of resistors, it might take several trays to provide enough compartments for all the values that an application might require. In this case, one might choose colors that indicate the resistance range of the resistors in the tray. For example:

Color coding the trays can be useful, but in many cases color coding by itself would not be enough to identify the contents of a tray. Using surface mount resistors as an example, there are many different physical sizes of resistors that all have the same resistance. So one might have four red trays each containing resistors in the range of 1.00 kΩ through 9.76 kΩ. The four trays would be for different physical sizes of resistors, for example, 0402, 0603, 0805, and 1206. A marking on the tray itself in addition to the markings on the compartment covers might be needed.

30 50 In order to reduce the chance of damage to static sensitive parts, the trayand covermay be manufactured of a material that is conductive enough to be static safe. Even for parts that are not static sensitive, if they are small enough, static charge buildup on the tray could be a nuisance. Small parts might cling to the covers or walls of the compartments due to static charge. Using a static safe material for the trays and covers can reduce or eliminate that problem.

In an embodiment in which the stored items are to be resistors, an approximately 5″×5″ tray can hold over 100 different values. The trays stack one on top of another, and a stack of seven trays holding the entire E96 series of resistor values from 1 Ω to 10 MegΩ is less than four inches tall. The parts are easy to locate because one small tray can have over 100 compartments and the compartment markings can be on the cover top. Although the contents of each compartment are not visible without removing the cover, putting the cover on backwards is a simple way to indicate an empty compartment. Existing pick and place machinery can be used to initially load the trays with parts and put the covers in place.

Although the different non-limiting embodiments have specific illustrated components, the embodiments of this invention are not limited to those particular combinations. It is possible to use some of the components or features from any of the non-limiting embodiments in combination with features or components from any of the other non-limiting embodiments.

The foregoing description is exemplary rather than defined by the limitations within. Various non-limiting embodiments are disclosed herein, however, one of ordinary skill in the art would recognize that various modifications and variations in light of the above teachings will fall within the scope of the appended claims. It is therefore to be appreciated that within the scope of the appended claims, the disclosure may be practiced other than as specifically described. For that reason the appended claims should be studied to determine true scope and content.